The optimization of the ratio of process investment was proposed. A screening classification was recommended prior to the primary preparation of thermal coal. The feasibility of this optimization was investigated. It is concluded that such optimization provides an excellent reference to the selection of beneficiation flowsheet for thermal coals. China is the largest consumer of coal in the world and has been a net importer since The measures were effective from Jan 1st, This article gives an introduction of background and main contents, analyzes the economic impact of the Measures especially on coal preparation in China and abroad.
The article compare the technical guide with interim measures, and propose next step policy China government should formulate to further strengthen coal quality management. In the current world mining climate the focus is on reducing cost and increase productivity. Simultaneously cost are being reduced, costs like spares holding, consumable costs and cheaper equipment alternatives with the end objective to reduce operating cost.
The question is with these initiatives taking place on the mines, what can be expected from the performance of the DMS cyclone? The paper will look at some factors that could be influenced by these initiatives, namely: the effect of near dense material, the effect of cyclone spigot wear and the effect of overloading the process by focussing on the medium to coal ratio and desliming screen capacity. The efficient utilization of energy is also touched on.
Processed coal has to adhere to an additional requirement of being able to pass through chutes, transfer points, hoppers and other handling or discharge systems with little or no difficulty to ensure efficient transportation thereof from a mine, through subsequent processing until delivery. Various handling difficulties such as irregular flow and decreased flow capacities occur as a result of the formation of dead zones, ratholing and arching. With the new worldwide focus on processing finer coal fractions it has also increased the need for understanding fines handling.
The true behaviour of a material during handling can only be understood by means of experience or by evaluating the handling performance, which requires extensive financial resources as well as time. However, if a Discrete Element Model DEM is readily available with which assesses the handling performance easily and quickly, it would result in improved plant operations as well as aid in hopper and chute design.
One of the most crucial aspects to consider when creating a validated DEM model of the coal flow is the coal particle characterization. With this particle characterization it is important to look at differences in shape, size and density as this will influence the coefficients of restitution, static and rolling friction.
The DEM software, used in this study, makes use of spherical particles with default values assigned for the coefficients of restitution, static and rolling friction. This study will aim to show what the influence of shape, size and density have on the various coefficients. Imagine that a sample of coal could be crushed unlimited times to the same or different top size; a different washability would be obtained for each crushing experiment.
Depending on the size and distribution of the raw coal components say vitrinite, inertinite, and mudstone , better yields for a low ash product are obtained as a top size is approached that is the same or smaller than the components that need to be liberated. As the virtual particle size decreases, the concentration or yield of the low ash product increases to a maximum, as the macerals are completely liberated from mineral matter.
In this paper a method is proposed to predict washability characteristics by simulating how coal will behave when crushed to different top sizes and with different virtual particle size distributions, from photographs. Growing demand on coal quality leads to the need of enhanced analysis tools for coal parameters. Therefore fast analysis of washability properties becomes a must in coal preparation.
The washability monitor OREGON which was introduced to the coal market in uses the combination of optical and radiometric methods for the fast determination of the washability curve. The concept of the analyzer is based on the measurement of a sample which will be processed in about 20 to 30 min. The sample is fed through the analyzer on a conveyor belt in a single layer.
Each particle is characterized by size and density.
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The washability characteristics of the full sample are then generated by Statistical evaluation. The method does not utilize any chemicals and the analysis can be performed even by untrained personell. Basic techniques which are used for analysis were first presented at ICPC It is obvious that basic combination of radiometric dual energy measurement leads to inaccuracies if ash composition undergoes variations.
This effect is well known from dual energies ash gauges.
Therefore the analyzer utilized a combination of dual energy and optical measurements. The paper discusses the improvements which are achieved by the triple parameter measurement concept in comparison to alorithms based on only two parameters. Existing research claims highly detailed simulation of stockpile buildup and reclaiming processes in blending beds based on sophisticated physics simulation. Optimization mechanisms integrating these simulations allow significant improvement over standard homogenization techniques using existing machines by adding real-time quality measurement and software-based stacker control.
The effect of the optimization system on the homogenization however is evaluated within the proposed simulation system itself, which, although based on real-world physics and simulated bulk material, has not been validated with measurements on actual physical matter yet. In this paper the simplifications are discussed which need to be made to physics simulation in order to be applicable in optimization systems and their implications on simulation quality and degree of realism.
For the first time this flexible and highly detailed real-world validation system for bulk material blending systems is available and utilized to evaluate existing simulation approaches. To control the mineral processing, e. Compared to main-belt installations an improved accuracy is obtained at a bypass stream, because the material stream can be crushed down to a constant particle size distribution and shaped to a constant cross section profile.
To minimize sample preparation, the material stream running across a bypass should be small, but the thin material layers require a re-design of the existing coal analyzers. However, the state-of-the-art microwave transmission moisture meters are designed for thicker material layers.
Therefore a novel microwave transmission moisture meter was developed. As in the past, it is based on the measurement of the microwave attenuation and phase-shift, but the new device also makes it possible to measure thin material layers all the way down to 3 cm thickness with a much higher accuracy. Technological management at coal preparation is carried out with the purpose of a technology choice, a combination of constructive and regime parameters of concentrating devices for getting of set quality coal concentrates at their maximal output for the given structure of initial products.
The decision of this problem is offered for carrying out with the help of information technologies which allow calculating variants of technological modes for acceptance of administrative technological decisions. For this purpose the mathematical model of coal preparation process as complex system is developed. It includes a coal composition, their compatibilities picked up by a principle at joint processing. Distribution of coal components is offered to describe by a square-law spline, and actual granulometric and fractional structure calculation to make for current ash level on the basis of the information available in a data base about earlier acting coal from the given mine or coal - analogue.
The choice of separation density for each machine class or coal at their separate dressing is carried out on the basis of theorem Reinhardt analytically with use of fraction ash-density dependences for each of coal and their composition. The developed mathematical model of the technological coal composition dressing circuit is based on balance of each narrow size and density fraction in view of probability of its transition in this or that product, determined by the separation characteristic of the concentrating device.
This model was a basis for drawing up of algorithm and development of computer calculation programs of qualitative and quantity indicator for rational mode variants. Pulverization is one of the most important stages of the electric power station, is often determined by the working capacity of the boiler and the entire plant as a whole.
Also in the process of pulverization in a ball mill grinding and transportation of raw materials for burning in boilers of fossil fuel burning power station spent about a third of all electricity for its own needs power. Existing methods for controlling the operation of the ball mill due to the instability of the parameters of the feedstock and the lack of control and accounting procedures mentioned parameters and other external disturbances cannot provide the optimum mode of operation. Therefore, to prevent collapse or emasculation drum mill at production tend to work on a much understated performance of the ball mill from its maximum possible.
In this regard, the decision of questions ensure optimal performance of the ball mill, and the quality of grinding products, as well as measures to reduce the specific consumption of electric energy and the cost of raw material grinding is an extremely urgent task. The paper presents the results of industrial investigations on radiometric control systems for refuse discharge from a jig. A new monitoring system based on the monitoring of the natural radiation emitted by the material in the separation zone of a jig compartment has been developed and tested in parallel with the radiometric density meter and the conventional float.
The correlation between the separation density monitored by the radiation density meter and the intensity of the natural radiation has been investigated. The correlation coefficient was ca. This shows that after a float as a measuring unit in the control system is replaced by a natural radiation monitor, good stabilisation of the separation density can be expected. The paper discusses advantages of such systems over the float based systems. This system can stabilise the desired quality of products without the intervention of an operator.
The authors presented a short description of two optical devices developed for the analysis of the cross-section of the coal transported by a belt conveyor. Devices applied a laser with a vision camera and infrared distance sensors. The results presented in the paper were collected during field trials at the coal preparation plant.
Tested devices were installed near the ash analyzer RODOS-W which uses natural gamma radiation for the ash determination and microwaves for the moisture measurement. The influence on ash and moisture measurements of the changing profile of the coal cross-section on the belt was investigated. Authors discussed advantages and disadvantages of both methods basing on results of field tests and analysed their usefulness for other purposes. The belt conveyor scale installed nearby the ash analyzer provides information about the amount of coal in the measurement zone.
The comparison of cross-section area with corresponding scale results was used to check the possibility to develop an optical scale without a strain gauge. Research covered areas such as screen optimisation, drain rates of multi-sloped screens, medium quality and the effect of medium quality on the DMC operation.
These projects have led to the development of instruments and techniques to measure the aperture and open area of screen decks, stroke and screen motion and the DMC overflow and underflow medium densities. Bretby Gammatech systems have been in the field providing customers with information since and seven years prior to this under British Coal. The method of on-line detection has not changed much over two decades.
However, the way we handle data most certainly has. This paper will describe the current suite of Bretby Gammatech equipment for detecting the ash in coal using the Natural Gamma method and what we can now do with this enormous amount of data being collected in terms of getting it to the people who need it in the most suitable format, wherever they may be in the world. We will look at recent installations around the world and how our Matrix Data Delivery is giving customers control of the Coal processing system, when they need it and where they need it.
Russia is one of the world leaders in coal production and processing. The coal industry has accumulated about 15 billion t of man-made solid wastes. The dumps of coal-fired thermal power plants contain about 1. Rational solving of the problem of efficient use of industrial waste depends on a number of factors, namely, material composition of waste, its aggregative state, quantity, technological characteristics, etc. The problem of non-waste technologies has ecological, resource saving, technological and technical, economical and organizational aspects.
There have been determined the areas of efficient use, technical requirements and innovative trends in the processing of technogenic coal deposits, main economical and technological conditions of processed wastes use as energy materials, in the production of construction materials, for recovery of alumina, rare and precious metals, production of ferroalloys, in the agriculture and others. The economical and technological conditions of cost-effective industrial implementation of processes of using slimes as fuel, e.
A problem of both ecological and economical value of coal recovery from coal-bearing overburden at surface coal mines has been solved. The prospective viability of ash and slag waste separation into organic and mineral components by flotation with a preliminary separation of aluminosilicate microspheres has been proved experimentally. A classified list of areas for the utilization of ash and slag waste of thermal power plants has been suggested.
According to our calculations, for the majority of cases related to production of TE marketable compounds or industrial concentrates it is economically feasible to use by-products called the primary concentrates, or PRTE, containing PVE of coal processing, i. There are proposed quantitative equations allowing selection of these products on the calculations basis by the programs of chemical thermodynamics or with help of experimental studies on laboratory pilot scale or industrial installations. Results of these studies can also be used to develop recommendations for the implementation of measures to reduce to acceptable levels the adverse environmental impact of PTE compounds formed during the processing of coals and other fossil fuels.
According to the studies, for almost all the PTE, the PRTE may be obtained as captured fly-ashes or their mixtures with slags with the minimum expenditures while coal combustion. The selection of combustion devices and modes of coal burning to produce primary concentrates with optimal composition for various PVE, and also development of proposals to reduce the adverse environmental impact of PTE compounds depend on their distribution between the combustion products. The 3rd group contains TE forming gaseous compounds in the high temperature zones of furnaces.
Under such conditions also a minimal hazardous effect of PTE of 1st and 2nd groups is reached. In order to achieve it for PTE of the 3rd group it is mandatory to utilize the special methods of gaseous compounds purification before releasing them into the atmosphere. The fly ash, a by-product of coal combustion in thermal power plants, is one of the most complex and abundant of anthropogenic materials, which large accumulations represent a serious environmental threat. To reduce the environmental burden and improve the economic benefits of energy production the science and industry focus on the transformation of coal combustion by-products into new functional materials.
The fly ash of power plant Pechora coal basin, Russia and reaction products were studied by modern analytical methods. As a result of the hydrothermal reaction several types of zeolites were synthesized from the fly ash: analcime, faujasite zeolite X and gismondine zeolite P. It was shown that the experimental conditions temperature, reaction time and alkali concentration have a significant influence on the type of zeolite and its content in the reaction products.
The series of experiments resulted in more detailed schematic diagram of zeolites and other phases. A revive of state of the art of Russian coal firing thermal power plants CTPP and coal consumption were done. The equipments of these plants are very old. The efficiency of electricity production is low, especially for combined heat and electricity CHP in summer regimes.
The leader electricity productions companies aspire to diversification of coal consumptions. The influences of coal quality on CTPP operation indexes, including ecological indexes and choosing of optimal technical decisions were considered. It was shown that combustion of enriched coals gives a small rising of technical indexes and a good rising of ecological indexes. These advantages are realized on utility size units with high supercritical parameters and long coal delivery. CFB boilers could be implemented for wastes of coals enrichment. Results of the development of a new generation of coal-fired CHP with high efficiency and low pollutions were done.
A technology for dry beneficiation of fly ash generated at coal-fired electric heat and power plants has been developed. Several samples of fly ash from different coal-fired heat and power plants were studied. The main processing technique, used for ash beneficiation in the performed studies, combined magnetic and electrical separation of ash in vibrofluidized state, permitting to significantly increase the separation process throughput rate and selectivity.
The studies of dry ash material composition and physical properties showed, that coal particles most commonly form aggregations with spheroidized magnetite-hematite, and are characterized by larger size in comparison with other particles of main mineral mass. In addition to that, fly ash is characterized by an extremely low bulk density and a unique conditional coefficient of internal friction, which is close to unity. The technology of coal preparation plants in modern Russia is characterized by using of closed water-sludge circuit to produce coal concentrate with the required parameters for moisture content without thermal drying of fine coal classes.
However, as part of shipped rock to the dump fine waste of coal preparation class The annual yield of the cake here is thousand tones. For a solution of this problem, the reducing of the release of enrichment waste and increasing of the marketable products on Tugnuy coal preparation plant it was suggested to use the technology of production and combustion of coal-water slurry fuel CWF on semi-industrial installation.
As a result 2 variants of filter-cake usage were suggested: - transfer on the CWF combustion boilers the existing boiler factory; - construction of mini CHP plants running on CWF, to provide electric and thermal energy needs of the Tugnuysky mine. This technology is applicable to virtually any kind of solid fuels and wastes. Due to the active aerodynamic structure of gas and fuel flows established in the furnace space, the vortex combustion technology can effectively reduce the sulfur oxides in the flue gas while burning high sulfur fuel. In this case, into the combustion space of the boiler is carried out simultaneous supply of fuel and sulfur-absorbing reagent SAR.
The article presents the research results of the possibility to suppress the release of sulfur oxides due to the suspension coal-water fuel CWF preparation with the simultaneous entry in the CWF along with the reagent-plasticizer of sulfer-absorbing reagent. The paper focuses on both Russian and international practices concerning the solution of ash and slag wastes processing and prospective areas of their application.
The results of lab and pilot plant tests on concentration ability of ash and slag wastes which were obtained during coal combustion at coal-fired CHP plants of Irkutskenergo JSC Irkutsk, Russia are presented. Ash and slag wastes, themselves a product generated by high-temperature thermal processing of the mineral matter of the coal during combustion in boilers, are a gray grainy mass. Dozens of ash and slag wastes millions of tons which generate annually during coal combustion at coal-fired power plants of the Irkutsk region can be fully processed with the generation of saleable products: iron concentrate, aluminum silicate product as well as products containing rare-earth, sparse and precious elements.
In this case, ash and slag wastes processing can be disposable. Pilot plant tests confirmed lab tests results in terms of the quality of the resulting iron-bearing concentrate and aluminum silicate product. Lab and pilot plant tests conducted demonstrated viability of the ash and slag wastes efficient processing. This resulted in their complete recycling and reduction in the environmental impact combined with profit generation from selling saleable products.
Economic calculations showed that the payback period for the construction of an ash and slag wastes concentration plant with the throughput of 1. The production line is equipped with environmentally friendly equipment produced in Russia. The coal industry has been moving toward elimination or size reduction of tailings ponds, as they pose major environmental and potential safety concerns. Thickening and dewatering of the dilute slurry to produce a high solids discharge has become the industry standard practice for processing coal tailings.
Large filter presses are normally used for dewatering the thickener underflow. However, filter presses are well known for their high cost, non-continuous operation, high maintenance, and large floor space requirements. Alternatively, high frequency fine dewatering screens have been applied to dewater thickener underflow, working in conjunction with filter presses. This process not only produces a high solids discharge, eliminating the need for a large number of tailings ponds, but it also reduces drastically the high cost of large filter presses, ultimately reducing the overall dewatering costs.
This paper describes two applications in which coal processors in China and India have benefitted from fine screening technology. The inefficiency of equipment and ambiguity of particle size will cause insufficient in-material of first flotation and overload in-material of second flotation. Technology of classifying hydrocyclone or sieve bend series has been applied in the process of classification, and flotation column in second flotation. A series of tests combined with practical application were conducted to verify the technology mentioned above.
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The result shows that ambiguity of particle size are acceptable if coarse and fine particle are separated by subsequent equipments, and application of classifying equipment such as sieve bend and classifying hydrocyclone, which is more flexible in operation, are also employed in the process of classifying flotation; If we focus on recovery rather than separation after separating coarse slime, classification particle size should be accurate, thus efficient classifying equipments like sieve bend series should be applied.
At the same time, in order to eliminate the effect of fine slime, desliming of coarse slime should also be considered. With high yield, low ash content and improved perfection index, flotation column as equipment of second flotation shows great advantages comparing with regular flotation machine. Pulp-mixing operation is the premise and safeguard to achieve effective mineralization and separation.
According to the present difficulties in slime flotation, the paper provided that pretreatment of pulp-mixing could be effective. With added force, the particle dispersion and surface modification could be achieved. Under good conditioning, the problems of high ash content and low coal recovery rate would be solved.
XVIII International Coal Preparation Congress
From the high efficient slime water slurry blending, the paper introduced the study progress of the mixing technology and theory for the slime water slurry and introduced the application and existing problems of the available slime water slurry blending equipment. Through the discussion of present pulp-mixing technology, research status and difficulties, high efficient slime water slurry blending equipment should be developed in order to meet the requirement of the fine and difficult preparation slime flotation technique.
Based on the above discussion, it pointed out that high-efficient pulp-mixing technique is a new research direction of mineral processing technology in future.
Three-product teetered bed separator, labeling as TPS, as an upgraded device, is emerging to get rid of an awkward facts thoroughly that traditional TBS could only produce two products, overflow and underflow. This paper introduces the structure characteristics of TPS with type I and type II, and its four possible applications. The float-sink analysis shows that TPS has the similar separation performance as heavy medium cyclone when treating easy-to-clean coal with Combining the washability of the feed, when clean coal with ash 8.
The disadvantage of traditional TBS could be exaggerated when treating difficult-to-clean coal due to only producing two products. The birth of TPS provides a better way of solving the problem. Mining and processing as well as handling of coal generate ultra-fine fractions of coal worldwide. The transport of this coal fraction is difficult, in particular the tendency to dust explosion attracts major technical and environmental challenges.
Agglomeration of coal dust is a potential way to facilitate safe transportation and economic use of the material. The main objective of agglomeration is to convert fine-grained materials into coarser products, so called agglomerates, pellets or granules. These products exhibit considerably improved properties with regard to transport, processing and use Pietsch, One possibility of agglomeration is the use of disc granulators. The ultra-fine coal will be energy efficiently formed into agglomerates by the addition of liquid binders, usually water, in an inclined rotating process chamber.
Due to the special movement of the material in the disc granulator a narrow grain size distribution of the product can be reached. This special movement of the material is caused by a set of selected parameters, such as inclination angle, rotational speed, dimension of the disc, moisture content and the material behavior itself. This paper presents experimental results of coal agglomeration in disc granulators. Exemplary flow-sheets are presented and the required investment and operating costs will be discussed. Industrial wastes resulted from production activity of mining, coal and metallurgical enterprises in the Ukraine make considerable amounts.
Waste disposal issues became the economic and environmental problems. Demand for solution of environmental problems combined with the urgent need to find additional sources of cheap dense solids for heavy-density media used in coal preparation gives rise to interest into the recycling of technogenic materials from metallurgical enterprises. Metallurgical production wastes were used as research subject. Electric furnace gas treatment slurries at the Krivoy Rog Central Mining Equipment Repair Plant were demonstrated to be polygenic formation of very complex mineral and petrography composition, which has majority of particles consisting of multiple crystalline or amorphous phases of various chemical composition and physical properties.
It is found that dry magnetic separation of electric furnace gas treatment slurries from the Krivoy Rog Central Mining Equipment Repair Plant allows separation of high-magnetic iron-bearing product with density of over 5. Conducted researches resulted in solution of the problem of dense solids production from the technogenic material of metallurgical enterprises, which meet the following requirements: water insolubility; mechanical abrasion resistance; chemical non-reactivity with water and products of separation; sufficiently fine size; relatively low cost.
The fundamentals of coal-water fuel composition containing a liquid organic waste: fusel oil, glycerol, oil sludge. The rheological properties of coal-water fuel composition based on various stages of coal metamorphism are developed. Determined the calorific value of coal-water fuel composition. It is proved that the use of dense organic liquids such as fusel oil as a dispersion phase fuel disperse systems based on coal calorific value accompanied by a significant increase in fuel abilities whole.
Usage of high-viscosity oil and glycerol sludge cannot completely replace the aqueous phase in the composition of the composite fuel based on coal while maintaining a low viscosity of fuel, which requires a search of other less viscous organic liquids which would be assigned to the class large mass waste. The paper presents the results of the studies conducted during the implementation of the project involving the identification of the quantity and quality of coal slurries deposited. Altogether 20 impoundments were analysed and samples of slurries were taken to determine their quality properties such content of ash, sulphur, volatile matter and calorific value Table 1.
XIX International Coal Preparation Congress & Expo
These properties do not always permit use of the slurries as fuel for energy generation. The best results were obtained using flotation process. Coal slurry deposits represent some energy potential defined by the heat content. The energy potential was calculated for each analysed slurry impoundment Table 3.
The energy potential of the obtained beneficiation products was also calculated. The results are shown in Table 4 along with the loss of energy potential in the process of slurry beneficiation. The studies and analyses made it possible to identify the impoundment that can be used as source of feedstock for the production of fuel for energy generation. The most frequent solution of water-slime industry in mines and companies working on coal output enrichment is linking watercourses from individual technological nodes into one stream of water-slime slurry.
The outcome of such solutions is water-slime mixture of averaged composition and physicochemical properties.
XVIII International Coal Preparation Congress
Among all studied various methods of coal concentrates extraction from slime — water slurries, the most interesting results are these of industrial significance obtained on mesh sieves. The new production of arched and centrifugal sieves the so-called OSO ,with minimum mesh size, enables selective coal concentrates extractions from coal slimes. The recovery of coal concentrates from flotation wastes is more difficult and most often the best results are ensured through application of flotation processes.
The conducted research of fine-grained coal wastes and side products of coal combustion lay a fundament to elaboration of new technology, pilot installations and incorporation completion. In addition to brief characteristics of the waste mining waste, tailings, and previously deposited waste , as well as technologies and installations to generate new useful products on their basis, present and forecasted for next years results obtained from research ecological projects and company plans for the future in this scope were shown.
The aim of actions taken in this field is to eliminate the problem of waste in mining companies as a result of their total use. Coal is a highly heterogeneous substance in terms of the inorganic and organic constituents and exhibits wide variability with respect to size and chemical composition of the particles. An estimation of the true value of the desired parameters of a bulk material, to certain of degree confidence, through analysis on a few grams of test sample is definitely a daunting problem.
The basic purpose of collecting and preparing a sample of coal is to provide a test sample which when analyzed will provide the test results representative of whole material. In the paper, the results of comparison of the of coal sampling made by three independent laboratories manual and automatically are shown.. Traditional way for energy production is coal fired power plants. Ultimate product of coal fired power plants is ash. Coal ash is valuable for operations like cement production and in future it might get more importance.
Ash properties changes with parent coal and operational parameters. Change in ash properties results in slagging or fouling problems inside the boiler. High temperature of combustion and low melting point of ash are the main reason of these problems. In this study 3 coal samples with moderate to high VM volatile matter content are observed in terms of ash melting behaviors. Abandoned coal mines influence on atmosphere, environmental monitoring of coal mining and processing territories and preventive measures resources optimizing XVIII International Coal Preparation Congress: 28 June July Saint-Petersburg, Russia, pp.
DOI: Vorobev, S. International experience of studies into integrated coal mining with underground method Gornyi Zhurnal, 5 , pp. Prospects of recovering and integrated development in Moscow lignite basin Gornyi Zhurnal, 2 , pp. Rubinstein, J. Those examples are references to articles in scholarly journals and how they are supposed to appear in your bibliography. Not all journals organize their published articles in volumes and issues, so these fields are optional.
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